Gel-like Phosphor Layer Shape Maintenance via Composite Resin
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Solution Overview
Problem
Phosphor layers made of gel-like or rubber-like resin in LED light-emitting sources tend to change shape over time, leading to deterioration and color unevenness issues.
Innovation Solution
A molded resin product with a translucent resin member containing a phosphor material, combined with a shape maintaining member made of a material with higher elasticity modulus, which is embedded or on the surface of the resin member to maintain its shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If gel-like or rubber-like resin is used for the phosphor layer, then the resin can be easily molded and applied, but the phosphor layer changes shape over time causing deterioration and color unevenness
Solution Approach 1:
The patent combines gel-like or rubber-like resin (providing ease of molding) with a shape maintaining member made of material having higher elasticity modulus (providing shape stability). This composite structure allows the phosphor layer to be easily manufactured while preventing shape changes over time, thereby resolving the contradiction between moldability and shape stability.
2Stability of the object's composition
If sealing resin members are used to prevent shape change, then the phosphor layer maintains its shape, but the device structure becomes more complex
Solution Approach 1:
The patent merges the phosphor layer with the shape maintaining member into an integrated structure. The shape maintaining member is embedded within or combined with the phosphor layer, eliminating the need for separate sealing resin members and reducing overall device complexity while maintaining shape stability.
3Device complexity
If conventional resins (epoxy, olefin) are used for sealing, then the sealing structure is simple, but the resin color changes due to heat from LED element over time
Solution Approach 1:
The patent changes the material parameter (elasticity modulus) of the shape maintaining member to be higher than that of the resin, enabling it to resist deformation from heat. This parameter change allows the sealing structure to maintain both simplicity and reliability under thermal conditions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively maintains the shape of the resin member for a long period, preventing color unevenness and ensuring consistent light emission.
Implementation Method 1
a phosphor material for converting the light emitted from a semiconductor light-emitting element being a light source into a desired color
Data Source
AI summary
A molded resin product or the like that is provided with a phosphor layer made of gel-like or rubber-like resin that can maintain its shape for a long period and that can be implemented easily. The molded resin product (phosphor layer 7) includes a resin member 17 made of a gel-like or rubber-like translucent resin including a phosphor material. The resin member 17 includes a shape maintaining member 19 that is formed in a lattice shape by line-like members 20 that are made of a material having a higher elasticity modulus than the resin member 17. The molded resin product (phosphor layer 7) is in the shape of a dome. The translucent resin is made of, for example, silicon resin, and the resin member 17 is gel-like.